Printhead module for additive manufacturing system

Abstract

A module for an additive manufacturing system includes a frame, a dispenser configured to deliver a layer of particles over a platen, an energy source to generate a beam to fuse the particles, and a metrology system having a first sensor to measure a property of the surface of layer before being fused and a second sensor to measure a property of the layer after being fused. The dispenser, first sensor, energy source and second sensor are positioned on the frame in order along a first axis, and the dispenser, first sensor, energy source and second sensor are fixed to the frame such that the frame, dispenser, first sensor, energy source and second sensor can be mounted and dismounted as a single unit from a movable support.

What is claimed is: 
     
       1. A module for an additive manufacturing system, comprising:
 a frame configured to be removably mounted on a support that is movable along a first axis; 
 a dispenser configured to deliver a layer of particles on a platen that is separate from the frame, or an underlying layer on the platen; 
 an energy source comprising a light source or electron gun configured to generate a beam to fuse the particles; and 
 a metrology system having a first sensor to measure a property of a surface of the layer before being fused and a second sensor to measure a property of the layer after being fused; 
 wherein the dispenser, first sensor, energy source and second sensor are positioned on the frame in order along the first axis, and wherein the dispenser, first sensor, energy source and second sensor are fixed to the frame such that the frame, dispenser, first sensor, energy source and second sensor can be mounted and dismounted as a single unit from the support. 
 
     
     
       2. The module of  claim 1 , wherein the first sensor is configured to measure a surface roughness or temperature of the layer. 
     
     
       3. The module of  claim 1 , wherein the second sensor is configured to measure a surface roughness or temperature of the layer. 
     
     
       4. The module of  claim 1 , wherein the first sensor is configured to measure a surface roughness of the layer and the second sensor is configured to measure a temperature of the layer. 
     
     
       5. The module of  claim 1 , further comprising a roller or blade extending along a second axis perpendicular to the first axis and configured to smooth the layer of particles. 
     
     
       6. The module of  claim 5 , wherein the blade is positioned between the dispenser and the first sensor. 
     
     
       7. The module of  claim 5 , wherein the blade is fixed to the frame such that the frame, dispenser, blade, first sensor, energy source and second sensor can be mounted and dismounted as a single unit from the support. 
     
     
       8. The module of  claim 1 , further comprising a heat source configured to heat the layer of particles to a temperature below a temperature at which the particles fuse. 
     
     
       9. The module of  claim 8 , wherein the heat source is positioned between the first sensor and the light source. 
     
     
       10. The module of  claim 8 , wherein the heat source is fixed to the frame such that the frame, dispenser, first sensor, heat source, energy source and second sensor can be mounted and dismounted as a single unit from the support. 
     
     
       11. The module of  claim 8 , wherein the heat source comprises an array of heat lamps. 
     
     
       12. The module of  claim 11 , wherein the heat lamps are disposed in a hexagonal closest packed array. 
     
     
       13. The module of  claim 11 , wherein the heat lamps are arranged with longitudinal axes at a non-zero angle relative to vertical. 
     
     
       14. The module of  claim 1 , wherein the energy source is configured to move a spot of impingement of the beam on the layer of particles along a second axis perpendicular to the first axis. 
     
     
       15. The module of  claim 14 , wherein the energy source is slidably mounted to the frame so as to be movable along the second axis by a motor. 
     
     
       16. The module of  claim 15 , wherein the energy source is configured to deflect the beam along the second axis perpendicular to the first axis. 
     
     
       17. An additive manufacturing system, comprising:
 a platen to support an object being fabricated; 
 a dispenser configured to deliver a succession of layers of particles over the platen, the dispenser movable along a first axis and including a slot or plurality of openings extending along a second axis perpendicular to the first axis, and wherein the dispenser is configured to dispense particles to a region on the second axis that extends beyond an edge of the dispenser; and 
 an energy source comprising a light source or electron gun configured to generate a beam to fuse particles in an uppermost layer of the succession of layers. 
 
     
     
       18. The system of  claim 17 , comprising a frame and a motor to move the frame along the first axis, and wherein the dispenser is mounted to the frame and the dispenser is configured to dispense particles at least up to an edge of the frame. 
     
     
       19. The system of  claim 17 , wherein the dispenser comprises a reservoir to hold the particles and a conduit coupled to the reservoir and extending along the second axis, the slot or plurality of openings extending from the conduit. 
     
     
       20. The system of  claim 17 , wherein the dispenser comprises a plurality of nozzles and the dispenser is configured to eject the particles in a carrier fluid through the nozzles.